Displaying items by tag: Mammoet

Purpose-built gantry system completes precise maneuver

Mammoet has successfully completed a heavy transportation and installation project in Indonesia. On behalf of General Electric, the team transported a 430t gas turbine and a 445t gas turbine generator at Tambak Lorok Power Plant, located in Semarang, Central Java. The loads were moved one-by-one a distance of 200m from their storage area to the power block building, using 10 axle-lines of SPMT in 4 file configuration.

At the installation area, the two pieces of equipment were maneuvered adjacent to their foundation and aligned centrally with it using SPMTs. Four strand jacks then slowly lifted the slings placed around the lifting trunnions to a sufficient height, raising the loads from the SPMTs. Next, the loads were slowly moved transverse to the center line of the foundations using a hydraulic system on top of the beams.

Mammoet transported and installed a gas turbine and gas turbine generator for General Electric’s Tambok Lorok power plant project.

Once the loads were aligned on the foundation lines to the customer’s satisfaction using self-propelled skid beams, they were slowly lowered onto the foundation. With the full weight of the equipment on the foundation, the slings were then removed from the lifting trunnions of the turbine and generator. This gantry system used was in-house designed and comprised four 200t strand jacks, 500t self-propelled skid beams, 150t skidding systems and customized lifting gantries.

This methodology was used so that operations could be completed within the customers’ given time frame and for the installation to still take place despite the tight space restrictions on site. Moreover, even though Mammoet had limited time available for transportation and installation, the team completed the scope of work promptly and with efficiency, due to its experts’ detailed project planning.

This gantry system used was in-house designed and comprised four 200t strand jacks, 500t self-propelled skid beams, 150t skidding systems and customized lifting gantries.

Mammoet’s work to install the generator and turbine will see an increase in electricity supplied to the Java-Bali grid. General Electric’s Tambok Lorok Power Plant is part of Indonesia’s 35,000MW grid expansion project, and will power over five million Indonesian homes upon its completion.

Mammoet
Mammoet helps clients with Smarter, Safer and Stronger solutions to any heavy lifting or transport challenge. We aim to develop long term relationships in order to understand their businesses and challenges best, so we can realize the most efficient and cost-effective approaches. We have a unique global network and an unparalleled fleet of equipment. Through deep and longstanding engineering expertise and the highest quality and safety standards in execution we bring an intelligent and flexible approach to projects across a wide breadth of industry sectors. Clients trust us to help them achieve feats that were once considered impossible, and we have often broken records in doing so.

For more information, visit www.mammoet.com

All modules lifted each as single piece with no change in each lifting position

Mammoet completed a heavy lift project using its PT 50 ring crane during an expansion project at India’s Paradip Refinery. Opened in 2016, the refinery is India’s most recent facility of its type.

For this project, a 646t De-ethylenizer, a 1,141t Wash Tower Column and a 1,185t Ethylene-Oxide Reactor needed to be lifted. Due to trust developed during a successful project back in 2019 which saw Mammoet lifted five major refinery components for Visakh Refinery’s modernization project, the company was selected for this heavy lift project at Paradip Refinery.

Mammoet’s PT 50 ring crane successfully lifted all three modules each as a single-piece at 2 different locations. The use of another lower capacity lifting equipment would have required each module to be split into two separate pieces. The use of PT 50 ring crane allowed installation lead time to be only two to three days instead of three weeks.

Mammoet’s PT 50 ring crane successfully lifted all three modules each as a single-piece and each from a single lift position. These actions resulted in time and cost efficiencies for the client and minimal use of on-site space without compromising on safety.

In addition, the ring crane’s high load capacity allowed it to lift multiple heavy items each from a single lift position. Therefore, it did not need to be relocated between lifts - shortening the overall project schedule relative to use of a smaller crane. Welding work was also not required by the team and this made the execution safer.

Scheduling changes were required due to regulatory measures brought in to combat coronavirus. The customer and Mammoet increased resourcing, with Mammoet’s crew extending their duration of stay in India. This allowed the project to be completed in an acceptable timescale for the customer, despite these complications.

The use of this ring crane resulted in time and cost efficiencies for the client. There was also minimal use of on-site space - without compromising on safety.

“The use of Mammoet’s PT 50 ring crane, over a crawler crane, allowed our components to be lifted each as a single module. This resulted in minimal disruption to our construction plans and brought about savings in our overall construction lead time,” said L&T Hydrocarbon Engineering.

The expansion plan at Paradip Refinery is expected to be completed in October 2021. This will add a Monothylene Glycol plant to the facility, broadening the range of products it can produce.

The first time an exhaust silencer replacement was lifted in a single piece

Mammoet has completed the replacement of a matured exhaust silencer for a gas turbine, at a gas-fired power station in Victoria, Australia. Removal of this 305t exhaust silencer was completed in a single lift. Therefore, this reduced the amount of time our client, an Australian energy company needed for their operations to be suspended to allow replacement to take place.

There were several challenges on site, which included the space available, how to interface with other activity crucial to the lift procedure, and the technical complexity of the lift itself - which needed to be very precise, despite the weights involved. The challenge lay in creating a methodology that was both strong enough to lift the loads and fast enough to keep delays to a minimum. 

So, the lift was meticulously planned, as every aspect of the lift was engineered weeks in advance. The crane’s position, boom laydown and location of the superlift tray were all marked out ahead of its arrival on site, ensuring engineering checks could be made that significantly optimized its setup time.

Minimizing the delay for adjusting the crane’s counterweight with auxillary cranes allowed the team to execute the project both efficiently and meticulously.

Mammoet proposed to use the Liebherr LG1750, because its suspended ballast system allowed the center 125t ballast tray to be disconnected from the outer 400t capacity ballast tray, once the load had been raised to the installation radius. This cut down on any delay so that the crane’s counterweight could be adjusted by auxiliary cranes and allowed the team to execute the project both efficiently and meticulously.

Secondly, the team faced the challenge of having to deal with the gas turbine’s tight shutdown schedule. Mechanical preparations could not start until the gas turbine was switched off and there was a narrow timeframe to complete lifting lug welding, so that the LG1750 crane could be assembled and be ready for lifting.

Mammoet overcame the above challenge by carrying out detailed site surveys in advance and planning an accelerated mobilization schedule. The LG1750 could then be brought onto site and set up quickly to minimize the required shut down period for the gas power plant.

Once the 205t used silencer had been removed, a new silencer was be fitted, comprising two pieces: a 168t base module and a 159t top module.

Throughout the project, Mammoet ensured the highest levels of operational efficiency, so that disruptions to day-to-day work were minimal, and that downtime for the power station was kept low. Furthermore, Mammoet was able to provide right equipment and expertise to efficiently setup and operate the LG1750 SX despite significant space restrictions on-site.

Completion of this replacement will see the gas-fired power station continue with full operation for power generation. The power station’s two generating turbines have an overall capacity of 566 Megawatts.

Mammoet
Mammoet helps clients improve construction efficiency and optimize the uptime of plants and installations. For that purpose, Mammoet offers solutions for lifting, transporting, installing and decommissioning large and heavy structures in the petrochemical, offshore, power, and civil industries. We believe our business is about time: uptime, turnaround time and time to market. To our customers, time is the currency that matters most. That’s why we strive to bring their deadlines forward. It’s an integrated daily effort, shared by everyone at Mammoet, in every aspect of our services: creative engineering, careful planning and safe delivery. For more information, visit www.mammoet.com.